Textile product having latent image that slowly appears following repeated washings

ABSTRACT

A textile product is disclosed having a latent image created from water-based ink which is applied using a screen printing process. The image is thereafter hidden underneath a second image created from a plasticizing emulsion such as plastisol ink which is partially cured. The partial cure causes a portion of the plasticizing emulsion to be removed from the textile product during washing and after repeated washings, the latent image becomes revealed.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates broadly to the field of printing images onto garments.

2. Summary of the Prior Art

Screen printing, sometimes referred to as “silk screening” is a well-known method for creating images such as lettering, graphics and images onto article of clothing such as t-shirts, jerseys, etc. A screen printing machine is used for creating the images onto articles of clothing.

Screen printing typically falls into one of two categories.

The first category is creation of the images using water-based ink. Water-based ink is used in which the ink dye penetrates into the fibers of the clothing. Thereafter, the article of clothing is dried, typically in a tunnel oven at about 420 deg F. for about 40 seconds to ensure permanence in the fabric. The resulting garment has a durable image.

The second category is creation of images using a plasticizing emulsion which is thereafter cured. Most common is the use of plastisol screen inks, and most preferably non-phthalate plastisol inks. Rather than penetrating the fabric as the case with water-based inks, plastisol screen inks are more of a coating which is applied onto the top or outer surface of the garment or clothing substrate. Upon application to the article of clothing, plastisol does not dry and requires heating, typically in a tunnel oven to about 350 deg F. for about 40 seconds or longer in order to achieve a full cure. The final product is images essentially permanently affixed upon the clothing substrate having a raised, plasticized texture.

Prior art screen printing processes have been used to permanently apply an image to an article of clothing.

SUMMARY OF THE INVENTION

The prior art method of making a permanent first image on an article of clothing using a typical screen printing process has been adapted so that a wash-removable second image is applied to the article of clothing, upon at least a portion of the first image, using a liquid plasticizing emulsion, preferably plastisol screen ink, and most preferably non-phthalate screen ink. Thereafter, the second image is heated to form only a partial cure of the plasticizing emulsion. The purpose of only a partial cure is to make the second image susceptible to partial removal when washing the article of clothing. Successive washings remove progressively more of the second image; revealing more of the underlying first image.

Described herein is: 1) a textile product having at least two images where the second image obscures at least a portion of the first image until the textile product is repeatedly washed a sufficient number of times before incrementally revealing a progressively greater portion of the underlying first image; and, 2) a method for applying an image to a textile article using water based inks and thereafter having the image temporarily hidden by application of a layer of a partially cured plasticizing emulsion. Preferably, the plasticizing emulsion is plastisol. Various colors of plasticizing emulsion can be used so long as the emulsion can obscure the portion of the first image covered by the emulsion.

As used herein, the term “plasticizing emulsion” refers to a liquid plasticizing emulsion such as plastisol screen inks that have not been heated to or above their gel point temperature.

The amount of plasticizing emulsion to use for the second image is the same quantity as is used in the prior art to fully cure an image on an article of clothing.

The term “textile article” refers to items that can have a first image applied by a screen printing process. Such items can include but are not limited to, an article of clothing such as a shirt or T-shirt, towel, wash cloth, etc.

The term “textile product” can refer to various items, including, but not limited to articles of clothing, towels, wash cloths, etc. that have at least a portion of a first image hidden by a second image as described above.

As used herein, the term “partially cure” means subjecting the second image created by the plasticizing emulsion to a temperature of between 220-240 F for between 35-45 seconds at atmospheric pressure.

As used herein, the term “image” can refer to any application of water-based ink or plasticizing emulsion onto a textile article using a screen printing process.

As used herein, the term “garment” refers to a textile product comprising two images created on the article of clothing; a first image; and, a partially cured second image created from a plasticizing emulsion applied directly upon at least a portion of the first image.

The first image is created using a screen printing process, preferably with water-based inks and then dried at a temperature to create a permanent first image which is resistant to repeated exposure to washings at high or low temperatures. Preferably, permanent, environmentally friendly non-toxic textile inks are used.

A second image is applied directly upon at least a portion of the first image. This second image, rather than using water-based inks, is applied using a screen printing process using plasticizing emulsion, preferably plastisol screen ink. Thereafter, rather than exposing the plasticizing emulsion to sufficient heat necessary to fully cure, a lower temperature is used to only partially cure the plasticizing emulsion. Since the plasticizing emulsion is only partially cured, it can be incrementally removed off the garment by repeated washings to progressively reveal more of the permanent first image that had been previously covered by the second image. While the screen printing process is well known, the methodology to create a garment that has a second image which can slowly be removed by a plurality of washings to reveal a latent first image is novel and non-obvious. Thus, this methodology produces a product that differs in kind from products normally produced using a screen printing and drying process.

The number of washings required for the second image to wear off is a function of the plasticizing emulsion used, temperature of the dryer used to cure the plastisol emulsion, time within the dryer, the temperature used during the washing of the garment, and the temperature at which the washed garment is dried. The lower the dryer temperature when partially curing the plasticizing emulsion, the fewer washings will be required for the first image to be revealed.

The second image thus described could also comprise multiple images. In other words, the second image is not limited to a single image covering at least a portion of the first image.

The second image could comprise two or more separate images covering respective areas of the first image. As used herein, “second image” refers to any deposit of plasticizing emulsion which covers at least a portion of the first image.

At least a portion of the first image is a latent image. Accordingly, it is desired that the first image become substantially viewable after a reasonable number of washings. Some may prefer that the first image become revealed after only one or two washings while others may prefer additional washings before the first image is revealed. This would be decided by the manufacturer and be based upon customer demand.

It has been discovered that an optimum temperature range to partially cure a plasticizing emulsion such as plastisol screen ink on an article of clothing such as a T-shirt is between 210 deg F. and 250 deg F. and most preferably between 220 and 240 deg F. Partial curing below 210 deg F. will yield a second image that is not dry to the touch, and make the article of clothing difficult to handle without smearing and damage, while a partial cure above 250 deg F. will produce a plastisol layer that is quite resistant to removal. The temperature to achieve a desired “partial cure”, as used herein to create the garment, means the drying temperature of the tunnel dryer or tunnel oven, within which the garment is placed for a sufficient period of time, such as about 40 seconds.

As described earlier, the rate at which the plastisol layer will wear off or fade also is dependent upon the temperature of the wash cycle. Washing with hot water will require fewer washings for the plastisol layer to disappear compared to washing the garment in cold water.

Garments, particularly thin apparel such as T-shirts, shirts, blouses, socks etc. can be adapted to incorporate plasticizing emulsion based non-toxic inks that can be used to create and temporarily hide water-based images. With repeated washing, additional portions of the second image are washed away to progressively reveal a greater portion of the first image.

The first image, sometimes referred to as the latent image, can be created using water based inks. The latent image, upon the article of clothing being dried, would be more resistant to fading or wear than the partially cured second image. The partially cured second image would be created upon the article of clothing to at least partially hide the first image. The second image is applied and partially cured to the desired temperature.

In another embodiment of the invention, latent images could be created using water based inks. The images would be covered by a partially cured image comprising a darker ink as part of a plasticizing emulsion that is designed to slowly wear off, dissolve or fade or become lightened after repeated washings, revealing the latent image.

In another embodiment of the invention, latent images could be created into an item of clothing; e.g., a T-shirt, having a latent image wherein portions of the image are made of different inks so that portions of the image will emerge after a different number of washings. For example, one portion may emerge after two washings while another portion of the latent image will emerge after 4 washings, etc. so that the full image develops only over time. This would enhance the “mystery” aspect of the first image; e.g., one portion of the image being the paws of an animal which would appear before the rest of the animal image.

In still another embodiment of the invention, following the application of the first image using a screen printing process with water-based ink(s), the second image is created from plasticizing emulsions partially cured at different temperatures. For example, if a portion of the second image is to last longer than other portions, that portion is a first application of a layer of plasticizing emulsion applied directly upon a portion of the first image and is thereafter partially cured at a pre-determined temperature. Next, a second application of a layer of plasticizing emulsion is applied upon a remaining portion of the first image not covered by the first application, and where the second application is thereafter partially cured at a temperature lower than the pre-determined temperature of the first application. By way of example, assume the first image is of an animal having penetrating eyes and the manufacturer desired the eyes to appear before the remaining portion of the latent image. A first application of plasticizing emulsion would be applied to cover the first image except for the penetrating eyes. The plasticizing emulsion would be partially cured at a pre-determined temperature. After cooling of the article of clothing, a second application of plasticizing emulsion would thereafter be applied upon the penetrating eyes of the first image and partially cured at a temperature lower than the pre-determined temperature of the first application. For this example, the areas of the second image partially cured at a lower temperature would wear off as a result of repeated washings before the other portions of the second image partially cured at a higher temperature. Thus, the penetrating eyes would be revealed before the remainder of the first image.

In another embodiment, after the water-based first image is applied, a transparent layer of plasticizing emulsion is applied upon at least a portion of the first image and thereafter fully cured. Thereafter, a second image is applied and partially cured. The purpose of the transparent layer is to maintain the vibrant color of the water-based ink so that fading of the color is substantially reduced as the garment is subjected to multiple washings.

In another embodiment, a textile article having a first image created by a screen printing process using water-based inks and dried at a sufficiently high temperature to permanently cure the first image to the textile article, wherein the improvement comprises:

a second image created on the textile article by a screen printing process using plastisol ink upon the textile article wherein at least a portion of the first image is obscured by the second image, the textile article thereafter dried in a dryer at between 220-240 F for between 35 to 45 seconds to partially cure the second image, so that the second image is susceptible to partial removal when washed and that the first image will become progressively more visible each time the textile article is subsequently washed, until the second image has been completely removed.

Images could be targeted at different age groups and sexes. For example, for small girls, a latent image of a princess could be placed on a T-shirt, and for small boys, the latent image could be of a zombie or superhero.

The second image could be slowly replaced with repeated washings with the first image. Examples include an image of a boy changing into a zombie, or an image of a girl changing into a mermaid.

A series of images; e.g., different animals, could be marketed for different garments, which would encourage parents to purchase multiple garments over time. Similarly, latent images designed for adults, with appropriate slogans, could be placed on T-shirts or other items; e.g., towels, to be used as surprise gifts. Different articles of clothing could also be treated such as underwear, socks, and pajamas.

The “delayed gratification” aspect of a latent image slowly appearing would especially keep children wondering and engaged. Use of a series of images; e.g., different animals, would further keep children engaged, as they would want the series on multiple clothing items to see all the animals appear.

An added advantage is that children would give up their clothing for washing at the appropriate time, because they will want to see how different it looks after it's clean once again, thus aiding parents in their attempts to keep their children's clothing clean.

In still another embodiment, the textile article comprises a first image already created using a screen printing or other process. In other words, a textile article such as a T-shirt can be purchased already having a first image that has been applied by screen printing, free-hand drawing, etc. At a time subsequent to purchase, the second image is applied directly upon at least a portion of the first image and partially cured to cover the earlier image and thus create the textile product.

Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the methods and garments described herein are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a prior art representation of a T-shirt having a first image created using a screen printing process;

FIG. 2 illustrates the appearance of the T-shirt of FIG. 1 having a second image applied to obscure the first image using a screen printing process;

FIG. 3 illustrates the appearance of the T-shirt of FIG. 2 following a second wash; and,

FIG. 4 is illustrates the appearance of the t-shirt of FIG. 3 after a third wash.

FIG. 5 is a block diagram illustrating a process 100 for creating a textile product having a permanent first image and a wash-removable second image.

FIG. 6 is a block diagram illustrating a method for removing the wash-removable second image.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The textile product described in this section is a garment and the textile article is an article of clothing, namely a T-shirt.

FIG. 1 is a representation of a T-shirt TS having a first image 10 created using a screen printing process.

A screen printing machine (not shown) is used to create first image 10 upon T-shirt TS. Water-based inks (CCI Boost Pigment Concentrate+water) are used and after the image is applied, T-shirt TS is passed thru a tunnel dryer (not shown) at about 420 deg F. For purposes of illustration, first image 10 is that of a dinosaur although any image can be created using this well-known prior art screen printing process.

A second image 12, opaque in appearance and oval in shape to represent an egg, is applied to T-shirt TS to obscure first image 10. A representation of the appearance of the T-shirt after application and partial cure of second image 12 is illustrated in FIG. 2. Following application and partial cure of second image 12, T-shirt TS, first image 10 and second image 12 are collectively referred to as garment G.

For determining the optimum partial cure temperature for the plastisol second image 12, multiple all-cotton T-shirts were used; each of which had a first image 10 depicting a dinosaur as described above.

The next step was to apply the plastisol second image to each T-shirt TS but partially cure the T-shirts separately at different temperatures.

After the T-shirts TS were printed with the dinosaur first image using the screen printing process and thereafter permanently dried using a tunnel dryer and thereafter allowed to cool, the screen printing process was used again to apply the second image using plastisol. In the example described herein, first image 10 is completely covered by second image 12 which is of an egg and the second image was comprised of silver plastisol (Wilflex Epic Silver Shimmer, manufactured by PolyOne, Inc.).

The following partial cure temperatures were evaluated: 180, 190, 200, 210, 220, 225, 230, 240, and 250 deg F. The objective was to determine how many washings would be required before the latent dinosaur image would come into view.

The T-shirts were thereafter repeatedly washed in a home washing machine. T-shirts were separated and washed separately. Some were washed on a normal cycle (59 min total; warm water wash; with one Tide 4-in-1 detergent pad added) and dried in a home drier on normal cycle (59 min).

Table 1 is a comparison of the number of washings required to reveal the latent image using various partial cure temperatures for a second image made from PolyOne 15370 PFX Epic Silver Shimmer Plastisol. Each partial cure was at the stated temperature in a tunnel dryer for 40 seconds:

TABLE 1 PolyOne 15370 PFX Epic Silver Shimmer Plastisol Cover Partial Cure # of Washes For # of Washes For Temperature 50% Image Reveal Full Image Reveal 180 F. N/A (too gummy) N/A (too gummy) 190 F. N/A (too gummy) N/A (too gummy) 200 F. 1 1 210 F. 1 1 220 F. 1 to 2 5 to 6 225 F. 3 to 4 7 to 8 230 F. 4 to 5  9 to 10 240 F. 6 to 7 >10  250 F. >10  >10 

For 180 and 190 deg F., the temperatures were insufficient to obtain an adequate partial cure. The plastisol was gummy to the touch prior to washing, and separated from the T-shirts and formed chunks in the washer as well as stained the T-shirts.

At the higher temperature levels of 240 and 250 deg F., the partial cure to the garment resulted in the plastisol adhering to the T-shirts so well that the second image remained intact after 10 washes.

At 200-210 deg F., substantially the entire first image was viewable after one wash.

At 220 deg F., some coloration of the dinosaur image appeared after one wash, but the outline of the first image remained somewhat obscured. After the second wash, between approximately 25-50% of the dinosaur image 10 was viewable in FIG. 3; and 75% or greater of the dinosaur image 10 is viewable after the third wash as illustrated in FIG. 4. There was little further development of the image after the fourth and fifth washes.

At a slightly higher temperature of 225 and 230 deg F., the plastisol image washed off more slowly, such that after three washes about 33% of the dinosaur image was visible.

Thus, the working temperature range for plastisol for achieving a desired partial cure to all-cotton T-shirts occurs between 200 deg F. and 230 deg F.

Based on the above, a partial cure temperature of about 220 deg F. for plastisol will cause the first image to become mostly visible after between about 4-6 washes.

With the top layer comprising silver plastisol alone, it was noted that, when orientating the T-shirt into certain positions under a light source, the reflectivity allowed portions of the dinosaur outline to be somewhat discernible. It then was determined that the addition of mottled brown or yellow plastisol spots to the silver plastisol would adequately cover the latent image. The removal characteristics of the brown, yellow, and silver plastisol were similar to those of the silver plastisol alone at the temperatures tested (200, 210, 220, 225, and 230 deg F.).

It also was determined that the wash-water temperature affected the removal of the plastisol. T-shirts with a dinosaur image and overprinted with silver plastisol partially cured to 230 deg F. were washed repeatedly on normal cycle in cold, warm, and extra-hot water (59 minutes total; one Tide 4-in-1 detergent pad added) and dried on normal cycle (59 min).

TABLE 2 Wash Temperature (Normal Cycle, 59 min); Plastisol Cured at 230 F. # of Washes For 50% # of Washes For Full Temperature Image Reveal Image Reveal Cold 5 to 6 >10 Warm 4 to 5  9-10 Extra Hot 2 to 3 8-9

For the dinosaur to be discernible it required approximately 5 to 6 washes using cold water, 4 to 5 washes using warm water, or 2 to 3 washes using hot water. Wash-water temperature thus affected the rapidity of plastisol removal, the slowest occurring in cold wash, and the greatest occurring in extra hot wash.

Preferably, TS is air dried, because dryers set to higher temperatures could continue to cure the plastisol and require more washings than if higher temperatures were not used.

Based on the above, about 220 to 240 deg F. is believed to be an optimum temperature range to partially cure the second image made of plastisol, because a higher cure temperature will require an unreasonably high number of washings to reveal the hidden image and thus may discourage the wearer. Consequently, a lower cure temperature will require fewer washings, and the novelty of the product may be lost if the hidden image is shown after only a couple of washings.

FIG. 5 is a block diagram illustrating a process 100 for creating a textile product having a permanent first image made with water-based inks and at least partially covered by a wash-removable second image consisting of partially cured plastisol in which the second image can be progressively removed by repeated washings to reveal the underlying portion of the first image.

A first image 10 using water-based ink, is deposited on TS by a screen printing process (102) and then permanently dried using a tunnel dryer (104). TS is allowed to cool and then TS undergoes a second screen printing process to receive a second image 12 covering at least a portion of first image 10 using a plasticizing emulsion such as plastisol (106). TS is then dried a second time using a tunnel dryer set at a temperature lower than the temperature used to dry the first image, preferably between 220-240 deg F. for about 40 seconds to partially cure second image 12 to made garment G (108).

FIG. 6 is a block diagram illustrating a process 200 for a method for making a latent image appear on a textile product initially covered by a coating of a partially cured plasticizing emulsion.

Providing garment G made by the process described in FIG. 5 for a third party to use (202).

Thereafter, garment G is washed thereby removing a portion of the wash-removable second image 12 (204).

The step of washing the textile product is repeated to remove additional portions of the wash-removable second image 12 to progressively reveal a greater portion of the first image (206). 

We claim:
 1. A textile article having a first image created by a screen printing process using water-based inks and dried at a sufficiently high temperature to permanently cure the first image to the textile article, wherein the improvement comprises: a second image created on the textile article by a screen printing process using plastisol ink upon the textile article wherein at least a portion of the first image is obscured by the second image, the textile article thereafter dried in a dryer at between 220-240 F for between 35 to 45 seconds to partially cure the second image, so that the second image is susceptible to partial removal when washed and that the first image will become progressively more visible each time the textile article is subsequently washed, until the second image has been completely removed.
 2. The textile product of claim 1 where the plastisol ink is a non-phthalate screen ink.
 3. The textile product of claim 1 where a layer of transparent plasticizing emulsion is applied directly upon a least a portion of the first image, using a screen printing process and thereafter fully cured prior to the second image being applied to the textile article.
 4. The textile product of claim 1 being a garment and the textile article being an article of clothing.
 5. A garment comprising: a first image applied to an article of clothing using a screen printing process with water-based ink and permanently dried; a second image applied directly upon at least a portion of the permanent first image using a screen printing process and plasticizing emulsion wherein: a first application of a layer of plasticizing emulsion applied directly upon a portion of the first image and thereafter dried at about 240 F for about 40 seconds to achieve a partial cure of the first layer of plasticizing emulsion; and, a second application of a layer of plasticizing emulsion applied upon a remaining portion of the first image not covered by the first application, and where the second application is thereafter dried at a temperature between 220 F and the pre-determined temperature of the first application for about 40 seconds to achieve a partial cure that will be susceptible to removal at a faster rate from the garment when washed than will be the partially cured first application. 